Soft magnetic alloy powder, dust core, magnetic component, and electronic device

Abstract

A soft magnetic alloy powder includes a main component of (Fe (1−(α+β)) X1 α X2 β ) (1−(a+b+c+d+e+f)) M a B b P c Si d C e S f , in which X1 is one or more of Co and Ni, X2 is one or more of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, and rare earth elements, and M is one or more of Nb, Hf, Zr, Ta, Mo, W, Ti, and V. 0≤a≤0.160, 0.020≤b≤0.200, 0≤c≤0.150, 0≤d≤0.060, 0≤e≤0.030, 0.0010≤f≤0.030, 0.005≤f/b≤1.50, α≥0, β≥0, and 0≥α+β≥0.50 are satisfied.

What is claimed is: 
     
       1. A soft magnetic alloy powder comprising nanocrystals and comprising a main component of (Fe (1−(α+β)) X1 α ×2 β ) (1−(a+b+c+d+e+f)) M a B b P c Si d C e S f , where:
 X1 is one or more of Co and Ni, 
 X2 is one or more of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, and rare earth elements, 
 M is Nb, 
 a, b, c, d, e, f, a, and β are atomic ratios, and 
 0.070≤a≤0.160, 
 0.020≤b≤0.200, 
 0.030≤c≤0.050, 
 0≤d≤0.060, 
 0≤e≤0.030, 
 0.0010≤f≤0.030, 
 0.005≤f/b≤1.50, 
 0.735≤1−(a+b+c+d+e+f)≤0.900, 
 α≥0, 
 β≥0, and 
 0≤α+β≤0.50 are satisfied, 
 wherein an average circularity of the soft magnetic alloy powder is 0.95 or more, 
 the nanocrystals have a bcc phase, and 
 a compound phase other than a bcc phase in the nanocrystals has a crystallinity of 2% or less. 
 
     
     
       2. The soft magnetic alloy powder according to  claim 1 , wherein the nanocrystals have a crystallinity of 25% or more. 
     
     
       3. The soft magnetic alloy powder according to  claim 1 , wherein 0.005≤f/b≤0.500 is satisfied. 
     
     
       4. A dust core comprising the soft magnetic alloy powder according to  claim 1 . 
     
     
       5. A magnetic component comprising the soft magnetic alloy powder according to  claim 1 . 
     
     
       6. An electronic device comprising the soft magnetic alloy powder according to  claim 1 . 
     
     
       7. The soft magnetic alloy powder according to  claim 1 , wherein the soft magnetic alloy powder is produced by an atomization method including spraying a molten alloy using a nozzle having a diameter in a range of 0.5 to 3 mm.